FUNDAMENTALS AND METHODS TAPPI · FLOATATION DRYERS Richard Luedtke Radiant Energy Systems, Inc....
Transcript of FUNDAMENTALS AND METHODS TAPPI · FLOATATION DRYERS Richard Luedtke Radiant Energy Systems, Inc....
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Building and Industrial Mat 2011 Spring Meeting
MAY 18 – 20
BASIC INDUSTRIAL DRYINGFUNDAMENTALS AND METHODS
Richard LuedtkeRadiant Energy Systems, Inc.Hawthorne, NJ
www.radiantenergy.com(973) 423-5220
TAPPI
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SESSION AGENDA
1. DEFINING THE PROCESS REQUIREMENTS2. “CONVENTIONAL” DRYING METHODS3. UNDERSTANDING THE DRYING/HEATING
PROCESS4. UNDERSTANDING CONVECTION DRYING5. UNDERSTANDING INFRARED DRYING 6. EQUIPMENT SELECTION: PROS AND CONS
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DEFINING THE PROCESS REQUIREMENTS
• Drying; Solvent vaporization/evaporation
• Curing; A final web/coating temperature requirement (normally following a drying requirement)
• Heating; Raising the temperature of a product: Substrate Heat set? Curing? Before lamination?; film, foils, etc.
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CONVENTIONAL TECHNOLOGIES USED FOR DRYING, CURING AND HEATING A WEB
• CONVECTION SYSTEMS– IMPINGEMENT DRYING– FLOATATION DRYING– THROUGH AIR DRYING– BATCH DRYERS/OVENS
• RADIANT HEATING/DRYING SYSTEMS– ELECTRIC INFRARED– GAS FIRED INFRARED
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A DRYER IS A “HEAT EXCHANGER”
Dryer/Oven System
Web and Coating
Finished Product
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Radiant Heat or Conditioned Hot Air
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Heating a Web
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TIME
Dry
er O
pera
ting
Tem
p.
Web Temperature
Dryer Temperature Set Point
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Drying and Heating Stages of a Coated Web
TIME
Sensible Heat Up
Constant Rate Drying
Cure-Heating
Web and CoatingTemperature
Dry
er O
pera
ting
Tem
p.
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DEFINING CONVECTION:
• “The transfer of heat by circulation of a gas or a liquid in contact with the object to be heated.”
• Convection dryers use ‘conditioned’ (Temperature and humidity controlled) hot air for heat transfer.
• Liquid Vaporization and Evaporation by both heat conduction and turbulent air flow.
• Convection dryers use a Nozzle array or ducted distribution of the air to uniformly heat the product as it passes through the confined Dryer atmosphere
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Richard LuedtkeRadiant Energy Systems, Inc.
Web and Coating
Finished Product
100% FRESH AIR FLOW Dryer/Oven System
Radiation Losses
Product Heat Load
Fuel Input to System
Exhaust Heat Load
CONVECTION DRYER HEAT LOADS – 100% FRESH AIR DESIGN
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Web and Coating
Finished Product
RECIRCULATED AIR FLOW Dryer/Oven System
Exhaust Heat Load
Radiation Losses
Product Heat Load
Fuel Input
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CONVECTION DRYER HEAT LOADS – Using 50% TO 90% RECIRCULATION
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IMPINGEMENT DRYERS
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Convection Air Drying Mechanics
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Laminar Layer at Drying Surface
Coating: Solids and Solvent - Substrate -
Moisture Removal; Exhaust/Recirculated Air Flow
Turbulent Air at Surface
Impingement Air at Supply Air DB Temp. (T1)
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Factors that impact Heat Transfer by Impingement:
• Velocity effect on Heat transfer is approximately proportional to the 0.6 power of the change. (V1/V2)0.6
• Drying air temperature increase or decrease will yield an approximate linear change in heat transfer.
• Humidity of the Supply air (Low Exhaust/High Recirculation) will reduce the heat transfer. This is due to a lowering of the dT used when a higher wet bulb temperature (higher moisture contentin the Exhaust/Return air) vs. the dryer supply temperature is present.
• Nozzle Distance from the web impacts the ‘Effective’ heat transfer (seen on the web surface) by approximately 10% per inchof distance; i.e.: A 1 inch nozzle to web distance will achieve 20% more theoretical heat transfer than a nozzle 3 inches away.
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Theoretical Impingement Heat Transfer vs. Temperature/Velocity
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
10,000
11,000
2,000 4,000 6,000 8,000 10,000 12,000Nozzle Velocity in AFPM
BT
U/H
r/F
t2 /Sid
e
500oF
450oF
300oF
350oF
400oF
150oF
200oF
250oF
6" on Ctr. Impingement style nozzle with 0.1" Slot Opening 1-1/2" from the Product
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IMPINGEMENT DRYER ADVANTAGES
� Heat transfer input (Velocity/Temperature) is somewhat independent of web handling issues.
� Can be easily arranged for multiple heat transfer zones, and also easily changed for different products requirements
� Accurate and uniform control of the dryer temperature for heating products irregardless of shape, size or color.
� Multiple Nozzle configurations and web pass configurations can be used with heat transfer to the top and/or bottom side of the web as required.
� Cost effective and can be adapted to multiple products with simple velocity and temperature adjustments.
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IMPINGEMENT NEGATIVES
� Roll or conveyor support needed along with the associated initial costs, maintenance issues, and web tension requirements for longer dryers.
� Possibility of Web Scratching or marking from contact with web support idlers.
� Lower rates of heat transfer and heating by conduction from the surface being impinged on (Thicker products will take longer to heat).
� Limitation of heat transfer velocities which may disturb or contaminate the coating.
� Generally slow to heat up to operating levels and slow to cool down which results in the limitation of maximum operating temperatures that may be dictated by the web properties.
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FLOATATION DRYERS
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COANDA EFFECT
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COANDA EFFECT ON AN AIRFOILHigher velocity and Coanda Effect cause Negative component on Wing
Coanda Nozzle Cross Section
Lowered pressure (negative component)
“A fluid flowing along a curved surface will tend to follow the surface”
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FLOATATION MECHANICS
Coanda Radius Effect yields nozzle to nozzle tension components
Pressure pads at nozzles develop Controllable Sine Wave Web path
Web Tension
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FLOATATION NOZZLE ARRAY
Exhaust/Return Air from Dryer
Exhaust/Return Air from Dryer
Heated Supply Air Ducted to Nozzles
Heated Supply Air Ducted to Nozzles
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FLOATATION DRYER ADVANTAGES
� Non-contact web support eliminating issues with marking or scratching.
� Eliminates the need for support rolls or conveyor with obvious benefits for running a saturated or 2-side coated web.
� Sine wave float eliminates edge curl.
� Positive web tracking through the dryer (‘self centering’) with minimum tension requirements.
� Accurate and uniform control of the dryer temperatures.
� Nozzle input from both sides of a coated web increases heat transfer capability and shortens the dryer length needed in most cases as compared to one side impingement.
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FLOATATION NEGATIVES� Lower rates of heat transfer and heating by
conduction from the surface being impinged on (Thicker products will take longer to heat).
� Boundary layer breakup is better with impingement, but, the Coanda creates parallel flow averaging of heat transfer.
� Limitation of heat transfer velocities which may disturb or contaminate the coating.
� Velocity and flow balance needed to float against line tension may limit heat transfer.
� Generally slow to heat up to operating levels and slow to cool down which results in the limitation of maximum operating temperatures.
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THROUGH AIR DRYING SYSTEMS
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THROUGH AIR DRYERS
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Supply Air
Exhaust Air
Supply Air
Exhaust Air
FLAT BED THRU AIR DRYER
ROTARY THRU AIR DRYER
HIGH TO MEDIUM PERMEABILITY (dP UP TO 6” W.C.)
MEDIUM TO LOW PERMEABILITY ( dP CAN BE OVER 20” W.C.)
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THROUGH AIR ADVANTAGES
� 2 to 3 times higher Air flow (Heat Transfer) than conventional convection.
� Intimate contact with product interior heats uniformly and rapidly.
� High thermal efficiency for Heating, cooling or Drying applications.
� Accurate and uniform temperature control to heat “through” the product.
� Extremely high evaporation rates from a combination of mechanical and thermal drying.
� Enhances the ‘Hand’ of Non woven materials.� Self tracking suction beds and Simple
operation.
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THROUGH AIR NEGATIVES
� Dependent on Permeability of the web.� Wet to dry permeability changes in the web
properties require multiple zones for Fan selection and efficient operation.
� Higher Blower Pressure drop needed for the higher air flow rates and to overcome product pressure drops; requires higher HP than convection in most cases.
� Mechanical losses of fiber and coating are carried in the through air stream.
� Most Products require a support conveyor or screen to maintain the ‘Flat’ bed with associated maintenance costs.
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RADIANT HEATING
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“The transfer of heat via electromagnetic waves between the heat source and the object to be heated.”
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Electromagnetic Energy Spectrum
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INDUSTRIAL PROCESS INFRARED
• Wavelengths used for Industrial Infrared heating applications range from 1.17 micron (4000º F) to 5.4 micron (500º F).� Short Wave Emitters – 2150º F to 4000º F� Medium Wave Emitters – 900º F to 2150º F� Long Wave Emitters – 500º F to 900º F
• Wavelength is inversely proportional to the temperature of the emitter. (i.e.: As temperature increases; the wavelength decreases)
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Infrared Spectrum
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Efficiency of Industrial Infrared Emissions
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Energy Reflected back from the Object
Energy Absorbed by the Object
Energy Transmitted Through the object
IR Emitter
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Stefan Boltzman Law to Determine Infrared Power
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The total energy radiated is equal to the
black body temperature to the 4th power
Q = kT4
Q = Emitted Energy
k = Constant (0.172 x 10-8)
T = Source temperature (°K)
For example: If the temperature of the emitter is increased by 50%, the energy emitted is increased by 500%
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Determining Wavelength
λ = C/T
λ – wavelength in microns
C - Constant (2898)
T - Source temperature (ºK)
Wien’s LawThe peak wave length of emission of an infrared heater can be calculated by Wien’s Law
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Typical IR Absorption Curves
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Infrared Advantages�Higher rate of heat transfer/Square Ft. compared to
Convection�Floor space savings due to higher density Heat
output�Easy to zone for uniform heating of the product and
range of widths being processed. �Fast response to changing process conditions�Quick start up and shut down in most styles of
heaters� ‘Infinite’ temperature control and ‘tune-ability’ with
Electric IR Source.� Lower initial capital and installation cost �Easily added to existing conventional dryers to
increase line speed� Infrared/Air dryers suitable for solvent based coatings
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Infrared Negatives�Some coatings may not be able to take advantage
of higher rates of heat transfer and may skin and blister
�Difficult to work with temperature sensitive substrates
�Electric Source Infrared Kw costs are generally higher than equivalent gas costs – (direct energy cost comparisons)
�Gas Fired IR has limited turn down and control. Sizing is job specific.
�Since IR is basically a surface conduction phenomenon, harder to dry heavier coatings rapidly without overheating the surface
�Almost essential to run trials in lab or on a pilot line to confirm dryer sizing and desired finish product.
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To Sum it All up …….
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Which Drying Method is the Best for the Application ??
�Convection ?�Infrared ?�Other ?
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ANSWER:NO SINGLE METHOD
� Product and Web handling issues should always be considered a part of the decision.
� Best Design and Efficiency will normally be a combination of the available technologies.
� Use and consider the advantages (and Negatives) of each.
� Input the features needed to handle special product requirements, cleaning, maintenance, and ease of operation.
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COMPARISON OF DRYING TECHNOLOGIES
Coa
ting
Moi
stur
e %
Time
Convection Dryer
Infrared Dryer
Combination Dryers
Richard LuedtkeRadiant Energy Systems, Inc.
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Excellence in Process Heating… Since 1985
175 North Ethel Ave. Hawthorne, NJ
07506
(973) 423-5220